Making and securing identification tags

Abstract

Various method of making RFID tags, RF-responsive antennae and other circuitry in flexible sheet form with touch fastener elements extending from one side of the sheet, for securing the tags. Some methods include continuous roll forming methods and/or the filling of molded channels with conductive compositions.

1 . An identification tag comprising 
 a flexible sheet-form base having a broad surface formed of resin;    electrically conductive material carried by the base, forming a conductive path and defining at least a portion of an antenna responsive to externally applied electromagnetic radiation oscillating at a predetermined frequency; and    an array of fastener elements extending from the broad surface of the base, the fastener elements arranged and constructed to engage mating fastener elements to selectively secure the tag.    
   
   
       2 . The identification tag of  claim 1  wherein the fastener elements are shaped to releasably engage exposed loop fibers associated with a supporting surface to which the tag is to be secured.  
   
   
       3 . The identification tag of  claim 2  wherein the fastener elements comprise raised projections of the resin of the broad surface of the base.  
   
   
       4 . The identification tag of  claim 3  having an entire thickness, measured from distal ends of the fastener elements to an exposed broad surface of the base opposite the fastener elements, of less than about 0.1 inch (2.5 millimeters).  
   
   
       5 . The identification tag of  claim 4 , wherein the entire thickness is less than about 0.05 inch (1.25 millimeters).  
   
   
       6 . The identification tag of  claim 1  wherein the fastener elements each have stems molded of resin contiguous with the resin forming the broad surface of the base.  
   
   
       7 . The identification tag of  claim 1  wherein the antenna is encased within the base.  
   
   
       8 . The identification tag of  claim 7  wherein the antenna is disposed between a first layer of resin forming the broad surface and insulating one side of the antenna, and a second layer of resin insulating another side of the antenna.  
   
   
       9 . The identification tag of  claim 8  wherein the first and second layers of resin consist of a single, seamless extent of a single resin material.  
   
   
       10 . The identification tag of  claim 8  wherein the first and second layers are of differing material properties.  
   
   
       11 . The identification tag of  claim 1  wherein the fastener elements each have a height, measured from the broad surface of the base, of less than about 0.05 inch.  
   
   
       12 . The identification tag of  claim 1  further comprising at least one discrete electrical component carried by the base and coupled to the antenna.  
   
   
       13 . The identification tag of  claim 12  wherein the electrical component comprises a circuit mounted in a sealed housing at least partially embedded in the base.  
   
   
       14 . The identification tag of  claim 13  wherein the sealed housing is fully disposed within the base resin.  
   
   
       15 . The identification tag of  claim 12  wherein the electrical component comprises a circuit in electrical communication with the antenna and at least partially electrically isolated by resin of the base.  
   
   
       16 . The identification tag of  claim 1  in elongated strap form, wherein the fastener elements are configured to secure the tag in place when the tag is wrapped about an object to engage itself.  
   
   
       17 . The identification tag of  claim 16  comprising a wrist strap.  
   
   
       18 . The identification tag of  claim 16  wherein the tag has a head defining an aperture adjacent one end of the tag, and wherein the fastener elements comprise a row of projections that cooperate with a feature of the head to prevent withdrawal of the tag from the aperture with an opposite end of the tag inserted through the aperture.  
   
   
       19 . The identification tag of  claim 16  wherein the fastener elements are configured to releasably engage other fastener elements of the tag when the tag is wrapped about an object to engage itself.  
   
   
       20 . The identification tag of  claim 16  wherein the base defines a discrete frangible region spaced from longitudinal ends of the tag and spanning at least one electrically conductive member of the tag, such that breaking the base at the frangible region renders the tag inoperable.  
   
   
       21 . The identification tag of  claim 1  defining a receptacle sized to receive an electronic component, the tag comprising electrically conductive connection surfaces positioned to establish electrical connectivity between the antenna and the received component.  
   
   
       22 . The identification tag of  claim 21  in combination with an electronic component disposed within the receptacle, the electronic component comprising a microprocessor and containing a unique component identification code.  
   
   
       23 . The identification tag of  claim 21  wherein the receptacle is bounded by at least one wall having component retention features that extend into the receptacle and prevent removal of a received electronic component.  
   
   
       24 . The identification tag of  claim 21  wherein the receptacle includes an electronic component removal slot arranged to permit sliding a received electronic component laterally out of the receptacle.  
   
   
       25 . A method of continuously forming a series of identification tags, the method comprising: 
 introducing a thermoplastic resin into a gap formed adjacent a peripheral surface of a rotating mold roll, the mold roll defining an array of cavities therein, the resin being introduced under pressure and temperature conditions selected to cause the resin to at least partially fill the cavities to form fastener element stems integrally with and extending from one broad surface of a strip of said resin; while    introducing a preformed strip into the gap, the preformed strip comprising a support substrate carrying a series of discrete electrical traces configured to form at least portions of antennae responsive to externally applied electromagnetic radiation oscillating at a predetermined frequency, the preformed strip introduced so as to cause the resin to bond with the preformed strip and form a laminate material having a flexible resin base carrying both an exposed array of fastener element stems and a series of antennae.    
   
   
       26 . The method of  claim 25  further comprising severing the laminate material into discrete identification tags, each tag containing an antenna and a multiplicity of exposed fastener elements.  
   
   
       27 . The method of  claim 25  wherein the electrical traces each comprise a continuous, coiled, flexible trace of conductive material forming a conductive path of length greater than a lateral extent of the antenna.  
   
   
       28 . The method of  claim 25  wherein the cavities of the mold roll are shaped to mold distal heads on the fastener element stems, the distal heads being shaped to overhang the broad surface of the strip of resin so as to be releasably engageable with exposed loop fibers.  
   
   
       29 . The method of  claim 25  wherein the gap comprises a nip defined between the rotating mold roll and a counter-rotating pressure roll.  
   
   
       30 . The method of  claim 25  wherein the support substrate comprises a film carrying the conductive material on a surface thereof, the resin being introduced to the gap directly adjacent the rotating mold roll, the film being introduced to the gap under pressure and temperature conditions which cause the film to become permanently bonded to the resin to envelop and electrically isolate the antennas.  
   
   
       31 . A method of forming a series of identification tags, the method comprising: 
 molding a continuous, flexible base of an electrically insulating thermoplastic resin, while forming a series of channels in a surface of the base;    at least partially filling the formed channels with a flowable, electrically conductive composition;    stabilizing the flowable composition in the channels to form a pattern of stable, electrically conductive traces within the channels; and    providing a series of discrete electronic circuits carried by the flexible base, each circuit electrically connected to a corresponding one of the traces to form a trace-circuit pairing;    wherein each trace-circuit pairing is responsive to externally applied electromagnetic radiation oscillating at a predetermined frequency.    
   
   
       32 . The method of  claim 31 , wherein the composition is stabilized in the channels by evaporating a solvent from the composition, or by radiating the composition in the channels with radiation selected from a group consisting of heat, ultraviolet radiation, and microwave radiation, or by subjecting the composition to reducing conditions, or by releasing reducing agents from capsules contained within the flowable composition.  
   
   
       33 . The method of  claim 31 , wherein molding the base comprises feeding the thermoplastic resin in a moldable form into a gap adjacent a mold roll.  
   
   
       34 . The method of  claim 33 , further comprising forming a field of loop-engageable fastener elements extending from the base by: 
 introducing the resin into the gap such that the resin fills a field of fixed cavities defined in the mold roll to form a field of molded stems;    solidifying the molded stems;    stripping the stems from the mold roll; and    forming loop-engageable heads on the molded stems.    
   
   
       35 . The method of  claim 31 , further comprising providing a field of loop-engageable fastener elements on the base exposed to releasably secure the base to a loop-bearing support.  
   
   
       36 . The method of  claim 31 , further comprising attaching an electrically insulating cover over the conductive traces, the cover attached to the base.  
   
   
       37 . A method of forming a flexible identification tag with integral touch fastener elements, the method comprising: 
 introducing an elongated flexible circuit strip including a substrate and a series of longitudinally spaced apart tag circuits carried by the substrate to a gap adjacent a peripheral surface of a mold roll having an array of stem forming cavities extending inwardly from the peripheral surface, while simultaneously    introducing a thermoplastic resin into the gap directly adjacent the peripheral surface under temperature and pressure conditions causing the thermoplastic resin to at least partially fill the stem forming cavities and to permanently bond to the substrate; and then    stripping the permanently joined thermoplastic resin and substrate from the mold roll to expose the fastener element stems.    
   
   
       38 . An electronically readable wrist strap comprising 
 an elongated and flexible strip of resin having opposite longitudinal ends and securable about a wrist of a wearer;    electrically conductive material carried by the strip and forming a conductive path that defines at least a portion of an antenna responsive to externally applied electromagnetic radiation oscillating at a predetermined frequency; and    electronic circuitry in electrical communication with the antenna and containing an electronically readable identification code;    wherein the strip defines a discrete frangible region spaced from the longitudinal ends and spanning at least one electrically conductive member of the strap, such that breaking the strip at the frangible region to remove the strap from the wrist renders the strap unreadable.    
   
   
       39 . The electronically readable wrist strap of  claim 38 , further comprising an array of fastener elements extending from the broad surface of the base, the fastener elements arranged and constructed to engage mating fastener elements to selectively secure the tag.  
   
   
       40 . The electronically readable wrist strap of  claim 39 , wherein the fastener elements comprise raised projections of the resin of the broad surface of the base.  
   
   
       41 . The electronically readable wrist strap of  claim 38 , wherein the antenna is disposed between a first layer of resin forming the broad surface and insulating one side of the antenna, and a second layer of resin insulating another side of the antenna.